I got the Aussie installed today
Included a write-up in the tech section as well for future reference.
Start with all the supplies and tools:
Aussie locker parts from box
Original side gear washers
Carrier center pin (I picked up a new one since the original was fairly worn)
Flat head screw drivers (small & large)
8mm open end box wrench and socket
More shop towels
something to drive center pin in/out (I used a ratchet)
I had my axles all the way out for a bearing/seal redo so first thing I had to do was re-insert my axle shafts:
Next - grease the teeth of the axle gears and the back (or outboard side) and place the washers to the outboard side of the gears. The grease will hold the washers:
Then put the axle gears in the carrier and the spacers to the axle gears - again, grease is your friend as it acts like a glue to stick the parts together:
Insert the center pin and usea flathead screwdriver to push the spacers outward toward the axles. Then use feeler gauges to measure the clearance between the center pin ad the spacers:
Check the manual for the proper spacing. I realized the gauge used in this pic wasn't the right one to be checking with - so pay close attention to what the manual reads. Then - record your spacing on the back of the manual. This is critical because if a problem arises the warranty is void without proper spacing and documentation. My spacing was .008:
Once you get the spacing recorded pull the center pin back out and the spacers:
Next - grease the teeth of the cam gears, the inside diameter of the cam gears, the slots and holes for the pins and springs, the springs and pins themselves, and set the spacers in the cam gears oriented so they will "cap" over the axle ends. Also, set the pins in the slots with the "step" going into the slot first:
Next - push the driver side axle through the driver axle gear and set the c-clip:
Then press the driver cam gear against the axle gear and seat the spacer over the axle/c-clip:
Then push the passenger axle into the axle gear, set the cam gear against the driver cam gear and orient the "slot" to insert the passenger c-clip. With the c-clip in place push the passenger spacer to "cap" over the axle/c-clip. Then press the passenger cam gear against the passenger axle gear:
Orient the two cam gears so the center pin holes, and pin/spring slot/holes line up. Use a small flathead to slide the pins across the slots and into the holes. Then, set the springs in place with one end seating on the now exposed "step" and the other in the outboard side of the slots:
Once this is done measure the spacing between the two cam gears:
And again - check the manual for specs and record it. Mine was .165:
Re-insert the center pin and tighten the set bolt w/ 8mm box wrench.
It is now installed:
But not done. Now it's time for the "spin" test. The manual explains in detail how this is to be performed - but a trick I used to hold the one side in position was to chock the tire with the mallet while I spun the opposite tire. The cam gears should "click" and allow the tire to spin in the opposite direction of the chocked tire:
Don't forget to record this step was done:
Once this is done it's time to button up the rear diff:
Once the diff cover is back on and fresh gear oil is put it the diff - take your new rear locked XJ out for a spin. It will be a clickety-clack SOB on turns but after a while you'll get used to how to drive with your new more capable XJ
This took about 2 hours from start to putting the diff cover on. I took my time, followed the manual EXACTLY, and kept my hands clean so I could take pics. It is as they say - easy as changing brakes.
Good luck to anybody wanting to do this and I hope the write-up is helpfull!